Table of Contents 1 Installation .............................................................................................................................................................................................5 1.1 1.2 1.3 1.4 ProCon HT 150 / HT 225 scope of delivery.................................................................................................................................5 Description ................................... ..................................................
6 Troubleshooting..............................................................................................................................................................................49 6.1 Error messages.................................................................................................................................................................. ..49 6.1.1 Error code..................................................................................................................
Important notice This manual is aimed at personnel from companies specialized in heating equipment. It contains the necessary information on installing and setting ProCon HT 150 / HT 225. This symbol is for instructions to follow with respect to your safety and that of others. This symbol is for instructions to follow for proper functioning of the appliance, the compliance with statutory provisions or for facilitating your work.
ProCon HT 150 / HT 225 1 1. Installation Installation • Overview of boiler control system 1.1 Scope of delivery ProCon HT 150 / HT 225 Gas condensing boiler, fully piped and wired, configured for natural gas group E (H) Included in the gas condensing boiler delivery are: ProCon Standard: - An “Installation/operation/maintenance” instruction manual - An outdoor temperature sensor with screws and plugs - Cascade controller RVA 47.
1. Installation The radiator flow temperature can be monitored as follows (control types): - Only outdoor temperature controlled - Outdoor temperature and time controlled - Outdoor temperature and time controlled with outdoor temperature effect over room unit QAA 70 - By means of a 0-10 V signal See installation/ operation/maintenance RVA 47 for more information. ProCon HT 150 / HT 225 • Domestic water sensor QAZ 21 94.19314-5002 (4 meters) 94.
1. Installation ProCon HT 150 / HT 225 • Pump overrun for domestic water pump • Safety temperature limiter STL (boiler) In order to use the residual heat of the boiler after it is charged with domestic water, the boiler control carries out a pump overrun. The pump overrun is carried out depending on the boiler temperature until it falls below an adjustable temperature or for up to a maximum of one minute.
1. Installation • Domestic water sensor If there is no sensor or if a short circuit occurs, an error warning (50) is triggered and all the functions associated with it are automatically deactivated. • Flue gas sensor These sensors must always be present. They are being constantly monitored. If there is a sign of irregularity, the boiler will automatically switch off.
2. Installation ProCon HT 150 / HT 225 2 In b etri e b n ahm e • Mounting the boiler 2.1 Choosing installation location The boiler can be operated dependent or independent of the room air. The construction allows the boiler to be installed on any loadbearing surface. The boiler room must be dry and frost-free. Do not contaminate combustion air through homogenous hydrocarbon (e.g.
2. Installation 2.3 Hydraulic connection The boiler is factory-equipped with an internal water deflector valve. ProCon HT 150 / HT 225 2.4 Gas connection • Explanations The boiler is a category II2ELL3P gas appliance. • Flushing out the heating system To prevent dirt in the gas-condensing boiler, an existing heating system must be flushed out thoroughly before installing the gascondensing boiler. MHG also recommends installing a dust collector in the return line of the heating system.
2. Installation ProCon HT 150 / HT 225 • Testing tightness Before start-up, the gas inlet pipe must be checked for tightness. Push the gas inlet pipe only up to the system shut-off valve. Note that the gas fitting cannot withstand the hightest pressure. • Changing the gas nozzle The boiler has been preset for natural gas E (or H). For natural gas LL (or L), the gas quantity must be adjusted via the compact gas fitting.
2. Installation MHG recommends room air independent operation because this operation mode has major advantages: - Additional energy saving due to preheating of the combustion air - No cooling-off of the building because there are no air inlets - and outlets.
2. Installation ProCon HT 150 / HT 225 Explanation: The term “low-rise building” is explained in building codes of the Bundesländer (states) under the paragraph titled “Terms.” According to the model building code, they are referred to as buildings in which the floor of any story where it is possible to have installation rooms, does not lie more than 7 meters above the ground surface at any point.
2. Installation • Installation type C43 C43 = - Gas appliance (Fan in front of the burner) with flue gas system that draws the combustion air from outdoors via a closed system (room air independent gas furnace). - Gas furnace with combustion air supply and flue gas discharge for connection to an air/flue gas system (across different ducts).
2. Installation ProCon HT 150 / HT 225 2.7 Maximum pipe lengths, Flue gas systems for ProCon HT 150 / HT 225 Flue gas outlet in a duct, connecting pipe 2 meters with 2x 87° - deflection Room air dependent operation mode ProCon Connecting pipe Riser max.
2. Installation ProCon HT 150 / HT 225 2.7.1 Room air independent operation – C33, C43, C53, C63, C83 Use only parts provided and approved by MHG to discharge the flue gases. • Installation type C33 Room air independent operation mode; ducted flue gas pipe - Gas appliance (Fan in front of the burner) with flue gas system that draws the combustion air from the outdoors via a closed system (room air independent gas furnace).
ProCon HT 150 / HT 225 2. Installation • Installation type C43 Room air independent operation mode; connection to an air/flue gas/duct system (LAS) - Gas appliance (Fan in front of the burner) with flue gas system that draws the combustion air from the outdoors via a closed system - (room air independent gas furnace). Gas furnace with combustion air supply and flue gas outlet for connection to an air/flue gas system (across different ducts). Fig.
2. Installation ProCon HT 150 / HT 225 • Installation type C53 Room air independent operation mode; with separate combustion air supply and flue gas outlet. The mouths are located in different pressure ranges - Gas appliance (Fan in front of the burner) with flue gas system that draws the combustion air from the outdoors via a closed system (room air independent gas furnace). - Gas furnace with separate combustion air supply and flue gas outlet: The mouths are located in different pressure ranges. Fig.
2. Installation ProCon HT 150 / HT 225 • Installation type C63 Room air independent operation mode; connection to a combustion air supply and flue gas outlet that has not been checked with the gas furnace. - Gas appliance (Fan in front of the burner) flue gas system that draws the combustion air from the outdoors air via a closed system (room air independent gas furnace). - Gas furnace designated for connection to a combustion air supply and flue gas outlet not checked with the gas furnace. Fig.
2. Installation ProCon HT 150 / HT 225 • Installation type C83 Room air independent operation mode; with flue gas connection to a joint flue gas system (reduced pressure operation) and separate combustion air supply from the outdoors - Gas appliance (Fan in front of the burner) flue gas system that draws the combustion air from the outdoors air via a closed system (room - air independent gas furnace).
ProCon HT 150 / HT 225 2. Installation • Installation Type B23 Room air dependent operation; Flue gas pipe ends in moisture-proof chimney - Gas appliance (Fan in front of the burner) with flue gas system that draws the combustion air form the installation room (room air dependent gas furnace). - The flue gas system can operate both under reduced pressure and under overpressure. Fig.
2. Installation • Installation Type B23 Room air dependent operation; flue gas pipe in chimney Fig.
2. Installation ProCon HT 150 / HT 225 Use only allowed lubricants to connect flue gas pipes. Make sure horizontal components have a 3% clearance from the boiler (3 cm by 1 meter in length), because condensed water could otherwise accumulate in the flue gas pipe. Condensed water in the flue gas pipe may cause operational malfunction.
2. Installation 2.8 ProCon HT 150 / HT 225 Electrical connection Caution 230 V: Make sure all electrical components are disconnected. Follow the applicable VDE regulations. The electrical connection must be checked by an electrical specialist before connecting to the mains. To make electrical connections, there is a terminal block on the back of the boiler. The terminal block is protected with a cover plate against direct contact. Remove the cover plate first.
2. Installation ProCon HT 150 / HT 225 • Outdoor temperature sensor • Bus clip-in OCI 420 Connect the outdoor sensor with a two-core cable (interchangeable) to the ATS terminal. See table below for cable profile: The bus module makes it possible for the boiler control system to communicate with RVA series external control devices Length [m] Minimum section [mm²] Up to18 18…35 0.125 0.25 35…50 0.5 Table 6: For resistance values see diagrams in Chap 7.
2. Installation ProCon HT 150 / HT 225 OCI 420... features an LED for indicating its status. It indicates the status of the LPD and various faults.
3. Start-up ProCon HT 150 / HT 225 3.1 Operating ProCon HT 150 / HT 225 ProCon HT 150 carries two 75 kW heat generator modules as well as a cascade and a heating circuit controller (RVA 47). Each heat generator module has a module control unit (LMU). The LMU controls and regulates the heat generator module. ProCon HT 225 carries three 75 kW heat generator modules as well as a cascade and a heating circuit controller (RVA 47). Each of the three heat generator modules has a module control unit (LMU).
3. Start-up 3.5 ProCon HT 150 / HT 225 Starting up ProCon HT 150 / HT 225 Before starting up, read the instruction manual carefully and makes sure that: - The gas pipe is adequately vented. If inadequately vented, heavy CO2 fluctuations will occur in the first minutes of operation. . The tank is well vented in the case of liquid gas equipment! The gas pipe is tested for tightness! Fig 16: Release the pump plugs Test the gas inlet pipe under pressure only up to the gate valve.
4. Hydraulic schemes 4.1 ProCon HT 150 / HT 225 Scheme 1: A pump heating circuit und domestic water storage tank with charge pump With ProCon HT 150 up to a max. o f 6 boilers can be cascaded. With ProCon HT 225 up to a max. of 4 boilers can be cascaded. Fig 19: A pump heating circuit and a domestic water storage tank with charge pump • Components Typ e Compo nent ProCon HT 225 Single Domestic water sensor 30 Code number 96.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Electrical connections Compo nent Outdoor sensor Connection to: OS terminal HC pump 1 Terminal HC pump Domestic water sensor Terminal DW Domestic water charge pump Terminal DW pump Annotation • Programming: The appliance can be operated with the default setting.
4. Hydraulic schemes 4.2 ProCon HT 150 / HT 225 Scheme 2: Two pump heating circuits and domestic water storage tank with charge pump With ProCon HT 150 up to a max. of 6 boilers can be cascaded. With ProCon HT 225 up to a max. of 4 boilers can be cascaded. Fig 20: Two pump heating circuits and domestic water storage tank with charge pump • Components Compo nent Typ e ProCon HT 225 Single Control 96.30000-7080 RVA 63.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Electrical connections Component Connection to: Annotation Outdoor sensor OS terminal Two-wire bus Bus terminal Bus connection between wall-mount enclosure and boiler HC pump 1 RVA 63.280 Q2, N, HC pump 2 RVA 63.280 Q6, N, Domestic water sensor RVA 63.280 B3, M Domestic water charge pump RVA 63.280 Q3, N, • Programming Change default setting according to specification in the table. Contro ller RVA 63.
4. Hydraulic schemes 4.3 ProCon HT 150 / HT 225 Scheme 3: A pump heating circuit, a mixing heating circuit and domestic water storage tank with charge pump With ProCon HT 150 up to a max. of 6 boilers can be cascaded. With ProCon HT 225 up to a max. of 4 boilers can be cascaded. Fig 21: A pump heating circuit a mixing heating circuit and domestic water storage tank with charge pump • Components Compo nent Typ e ProCon HT 225 Single 96.30000-7080 Domestic water sensor QAZ 21 Control unit RVA 46.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Electrical connections Component Connection to Annotation Outdoor sensor OS terminal HC pump Terminal HC pump Domestic water sensor DW terminal Domestic water charge pump Terminal DW pump Two-wire bus Bus terminal Bus connection between wall-mount enclosure and boiler Flow sensor MK RVA 46.531 B3, M Pump MK RVA 46.531 Q2, N, Mixer motor MK RVA 46.531 Y1, Y2, N, • Programming Change default setting according to specification in the table.
4. Hydraulic schemes 4.4 ProCon HT 150 / HT 225 Scheme 4: Two mixing heating circuits and domestic water storage tank with charge pump With ProCon HT 150 up to a max. of 6 boilers can be cascaded. With ProCon HT 225 up to a max. of 4 boilers can be cascaded. Fig 22: Two mixing heating circuits and domestic water storage tank with charge pump • Components Compo nent Typ e ProCon HT 225 Single 96.30000-7080 Domestic water sensor QAZ 21 Control unit RVA 63.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Electrical connections Component Connection to Annotation Outdoor sensor OS terminal Two-wire BUS BUS terminal BUS connection between wall-mount enclosure and boiler Flow sensor MK 1 RVA 63.280 B1, M Pump MK 1 RVA 63.280 Q2, N, Mixer motor MK 1 RVA 63.280 Y1, Y2, N, Flow sensor MK 2 RVA 63.280 B12, M Pump MK 2 RVA 63.280 Q6, Mixer motor MK 2 RVA 63.280 Y5, Y6, N, Domestic water sensor RVA 63.
4. Hydraulic schemes ProCon HT 150 / HT 225 4.5 Scheme 5: A pump heating circuit, three mixing heating circuits and domestic water storage tank with charge pump With ProCon HT 150 up to a max. of 6 boilers can be cascaded. With ProCon HT 225 up to a maximum of 4 boilers can be cascaded. Fig 23: A pump heating circuit, three mixing heating circuits and domestic water storage tank with charge pump • Components Typ e Compo nent ProCon HT 225 Single Code number 94.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Electrical connections Component Connection to Annotation Outdoor sensor OS terminal HC pump Terminal HC pump Two-wire bus Bus terminal Bus connection between wall-mount enclosure and boiler Flow sensor MK 1 RVA 46.531 B3, M Pump MK 1 RVA 46.531 Q2, N, Mixer motor MK 1 RVA 46.531 Y1, Y2, N, Flow sensor MK 2 RVA 63.280 B1, M Pump MK 2 RVA 63.280 Q2, N, Mixer motor MK 2 RVA 63.280 Y1, Y2, N, Flow sensor MK 3 RVA 63.
4. Hydraulic schemes 4.6 Scheme 6: Two cascades, one pump heating circuit and domestic water with charge pump With ProCon HT 150 up to a maximum of 6 boilers can be cascaded. With ProCon HT 225 up to a maximum of 4 boilers can be cascaded.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Components Compo nent Typ e Code number ProCon HT master Cascade 96.30000-7082 ProCon HT slave Cascade 96.30000-7084 Water deflector Domestic water sensor Annotation Included in the scope of delivery: Outdoor sensor QAC 31, Cascade controller, 2 strap-on sensors QAD 26 (s. Total price list) QAZ 21 94.19314-5002 Length 4 m 94.
4. Hydraulic schemes ProCon HT 150 / HT 225 4.7 Scheme 7: Two cascades, one pump heating circuit, one mixing heating circuit and domestic water with charge pump With ProCon HT 150 up to a maximum of 6 boilers can be cascaded. With ProCon HT 225 up to a maximum of 4 boilers can be cascaded.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Components Compo nent Typ e Code number ProCon HT master Cascade 96.30000-7082 ProCon HT slave Cascade 96.30000-7084 Water deflector Control unit Included in the scope of delivery: Outdoor sensor QAC 31, Cascade controller, 2 strap-on sensors QAD 26 (see Total price list) RVA 63.280/380 94.80100-5510 Wall-mount enclosure for RVA 63 Flow sensor for MK QAD 26 Domestic water sensor Annotation 94.85301-5004 94.19314-5005 QAZ 21 94.
4. Hydraulic schemes 4.8 Scheme 8: Two cascades, four mixing heating circuits and domestic water storage tank with charge pump With ProCon HT 150 up to a maximum of 6 boilers can be cascaded. With ProCon HT 225 up to a maximum of 4 boilers can be cascaded.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Components Compo nent Typ e Code number ProCon HT master Cascade 96.30000-7082 ProCon HT slave Cascade 96.30000-7084 Water deflector 2 Control units Annotation Included in the scope of delivery: Outdoor sensor QAC 31 as well as Cascade controller RVA 47, 2 strap-on sensors QAD 21, bus module OCI 420 (see Total price list) RVA 63.280/380 2 Wall-mount enclosure for RVA 63 3 x Flow sensor QAD 26 Domestic water sensor QAZ 21 94.80100-5510 94.
4. Hydraulic schemes ProCon HT 150 / HT 225 • Programming Change factory setting as specified in the table. RVA 47 Contro ller Line Set point value Annotation 17 --- Heating circuit switched off Boiler control 4 605 5 Device address Boiler control 5 605 6 Device address Boiler control 6 605 7 Device address 80 0 67 00.01 140 1 Device address 141 1 Segment address 148 2 Adjustable system time 80 0 67 00.
5. Maintenance ProCon HT 150 / HT 225 5.1 Oil and burner control units should be inspected once a year. According to DIN 4755 and DIN 4756: Maintenance • Display of maintenance request After 12 months of operation, the maintenance message (105) will appear in the multifunction display (12) of the control unit. Code „1“ and „05“ will be displayed alternately.
5. Maintenance ProCon HT 150 / HT 225 • Check the hydraulic pressure switch • Clean the combustion chamber / heating surfaces Put the appliance in the heating mode and slowly release the system pressure. Below 0.5 bar the pressure switch should turn off the burner. In the multifunction display of the control unit the error display will be permanently on. The codes „1“ and „19“ will appear on the multifunction display alternately. During system refill (pressure > 0.
6. Troubleshooting ProCon HT 150 / HT 225 6.1 Error messages In the case of a permanent LMU error status..., the error display (16) will be on permanently. In addition to that, the diagnosis code sent out through flashes on the multifunction display (12). To clear the error status, press the release button (7) (> 2 s). 6.1.
7. Technical documentation 7.1 ProCon HT 150 / HT 225 Static delivery head ProCon HT 150 / HT 225 The boilers are equipped with an internal water deflector. Ignore the hydraulic resistance of the water deflector. 7.2 Resistance curve of flow sensor, domestic water sensor, boiler and flue gas sensor 1.900 1.800 1.700 1.600 1.500 1.400 1.300 1.200 1.100 1.000 900 800 Temperature [°C] 700 -50 -25 0 25 50 75 100 Fig.
7. Technical documentation ProCon HT 150 / HT 225 7.3 Outdoor sensor resistance curve 1.900 1.800 1.700 1.600 1.500 1.400 1.300 1.200 1.100 1.000 900 800 Temperature [°C] 700 -50 -25 0 25 50 75 100 125 150 175 Fig.
7. Technical documentation 7.4 ProCon HT 150 / HT 225 AGU 2.
7. Technical documentation ProCon HT 150 / HT 225 • Operation phase display (Display level A4) You can show the operation phases corresponding to the sequence diagram LMU on AGU2.361 via display (12) by pressing the button (8) and At the same time, you are specifying the following coordination between the display code and LMU…phase description: Display Meaning Internal operation phases LMU...
7. Technical documentation ProCon HT 150 / HT 225 Basic processes: 7.4.1 Display mode and programming AGU 2.361 • Arriving at the display mode P To arrive at the display mode press and hold (> 3 sec) the display mode button (8) . (Display (12): A...). Continue to hold down the button to reach the different display levels b, C, d, P as well as A once again. Release the button at the desired display level (A, b, C, d or P).
7. Technical documentation ProCon HT 150 / HT 225 7.5 Display levels You can only call up the parameters of Groups A, b, C and d. You can also change Group P. Display level LMU... Variable name Description Display ¹) 15 P 14 General information (End user level) ²) A0 Message code A1 TkIst A2 TbwIst1 A3 Pressure A4 Op.
7. Technical documentation 7.5.1 Setting the heating capacity with QAA 73 You can set the heating capacity alongside the above-named settings on QAA 73. QAA73... Available AGU2.361 Available Boiler set point value TvSollMmi Capacity setting QAA 73...- Indoor set point value knob You can end the control stop function by pressing the chimney sweep button (9) (> 1 sec). Changing the max.
7. Technical documentation ProCon HT 150 / HT 225 Line Level Function 536 Specialist Max. speed at max. capacity in heating operation (upper speed limit) Maximum modulation level in heating operation 541 Specialist (LmodTL <= PhzMax <= LmodVL) 3) 542 Specialist Min. boiler capacity in kW 5433) Specialist Max. boiler capacity in kW Pump - overrun time, max.
7. Technical documentation Line Level 619 Specialist 620 Specialist 621 Specialist 622 Specialist 630 Specialist ProCon HT 150 / HT 225 Function Funct. output1 Relay clip-in. (0: Off, 1: Message display., 2: Alarm signal, 3: Operation message, 4: ext. Transf., 5: Q2Y2, 6: DW Circ.., 7: Curtain, 8: hydr. switch, 9: RegCI, 10: Basic funct. K2, 11: DW- Loading Through (Durchldg), 12: Analogue threshold) Funct. output 2 Relay clip-in.
7. Technical documentation ProCon HT 150 / HT 225 • Parameter 536 Setting the maximum heating capacity • Parameter 606 Segment address It specifies the speed for the max. heating capacity of a heat generator module and enables the reduction of the max. module capacity. ProCon HT is a system made up of several control units (LMU, RVA 47). This system is the heat generator segment and can be constructed from a single ProCon HT or several ProCon HTs connected in cascade.
7. Technical documentation 7.7 Electrical terminals ProCon HT 150 / HT 225 Fig.
7. Technical documentation ProCon HT 150 / HT 225 7.8 Technical data RVA 47 Voltage supply Rated voltage Rated frequencies Power consumption AC 230 V (±10 %) 50 Hz (±6 %) Max.
7. Technical documentation 7.9 Fig.
7. Technical documentation ProCon HT 150 / HT 225 7.10 Technical data ProCon HT 150 / HT 225 Product ID number Category Typ e Volume of hot water in boiler ProCon HT 150 H ProCon HT 225 H CE II2ELL3/P CE II2ELL3/P l 30 35 Boiler weight kg 250 270 Measurements (L x B x H) mm 1650 x 680 x 1030 Hot water connections FlangeDIN 2631 DN 40 / 48.
7. Technical documentation 7.11 Component diagram of boiler body, Gas/air duct and fan Fig.
ProCon HT 150 / HT 225 7.12 7. Technical documentation Component diagram of frame and panel Fig.
7. Technical documentation 7.13 Component diagram of flue gas collector Abb.
ProCon HT 150 / HT 225 7.14 7. Technical documentation Component diagram of water deflector and boiler body Abb.
7. Technical documentation ProCon HT 150 / HT 225 7.15 Legend for exploded diagram Pos.
7. Technical documentation ProCon HT 150 / HT 225 Pos. Description o.A. 44.6 44.7 44.13 44.15 44.16 o.A. 45 46 o.A. 47 48 o.A. 48.7 49 50 51 52 53 54 55 56 57 58 59 60 61 63 65 66.1 66.2 66.3 66.4 66.5 66.6 66.7 66.8 66.9 66.10 66.11 66.12 66.13 66.14 66.15 66.
7. Technical documentation Pos. 66.19 66.20 66.21 66.22 66.23 66.24 66.25 66.25.3 66.26 66.27 66.28 66.29 66.30 66.31 67 68 o.A. 69 70 71 72 73 74 75 76 o.A. 77 78 79 79 80 81 o.A. 82 83 84 85 86 87 88 89 90 91 o.A.
7. Technical documentation ProCon HT 150 / HT 225 Pos. 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 o.A. o.A. o.A. o.A. o.A. o.A. o.A. o.A. o.A. o.A. o.A. o.A. o.A. o.A. o.A.
6. Warranty 8.1 Warranty ProCon gas condensing boiler by MHG will function smoothly if you install and start it up properly. ProCon HT 150 / HT 225 8.2 Replacement parts Use only original parts by MHG for replacement. Always provide serial number when ordering parts. The warranty is valid for 2 years from start of operation and at the most 27 months from delivery date.
8. Warranty ProCon HT 150 / HT 225 EC Model Declaration of Conformity Hamburg, November 24, 2005 MHG Heiztechnik GmbH certifies herewith that the gas condensing boiler (condensing-circulation boiler) specified below Series ProCon HT 150 / HT 225 Model No. CE approved correspond to the model described in the EC model test certificate. The devices meet the relevant requirements of the Gas Appliance Directive 90/396 EWG (06.1990) and DIN EN 677 (06.1998) and DIN EN 483 (06.2000) test standards.
Notes 74 ProCon HT 150 / HT 225
HT 150 / HT 225 GWB 75 Notes 75
